Method for inspecting a turbine engine rotor with a rotor disc cavity inspection apparatus

ABSTRACT

Turbine engine rotor corresponding thru-bolts and disc cavities are inspected with a camera inspection system that includes one or both of a thru-bolt male threads inspection apparatus and a rotor disc cavity inspection apparatus. The disc cavity inspection scope apparatus is insertable in one or more of the desired rotor disc cavities and orients an attached inspection camera field of view generally transverse to the circumferential wall in the rotor disc that defines the cavity. Preferably inspection scope apparatus insertion into the disc cavities is performed with a motion control system that monitors spatial position of the camera field of view relative to the recess circumferential wall. The plural camera cavity circumferential wall images are desirably combined to form a composite image of a desired portion of or the entire disc cavity circumferential surface, which aids their inspection evaluation and provides an archived composite image of the surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application incorporates by reference in its entirety United Statesutility patent application entitled “METHOD FOR INSPECTING A TURBINEENGINE ROTOR WITH A THRU-BOLT THREADS INSPECTION APPARATUS” filedconcurrently herewith, Ser. No. 14/190,781.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to methods and apparatus for inspecting turbineengine rotor thru-bolts and their corresponding rotor disc cavities.More specifically, embodiments of the invention are directed to camerainspection apparatus and methods for inspecting thru-bolt male threads,thru-bolt outer circumference and the corresponding mating rotor disccavity walls of a combustion turbine compressor or turbine sectionrotor. Embodiments of the invention facilitate creation of compositeside-by-side images of the disc cavity wall and mating thru-bolt outercircumference as well as the bolt male threads profiles, for example todetermine future serviceability during turbine engine maintenance.

2. Description of the Prior Art

Known turbine engines have rotors comprising a plurality of seriallyaligned rotor discs with a circumferentially spaced array of axiallyaligned rotor disc cavities. The rotor discs are axially retained bythru-bolts that are inserted in the axially aligned disc cavities fromone axial end of the rotor. Referring to the combustion turbine engine20 of FIG. 1, the compressor section rotor 22 has four rotor discs 24that are retained by thru-bolts 26 and mating nuts 28 on both ends ofthe bolt. During periodic maintenance outages the rotor 20 is inspectedfor serviceability. During rotor service the rotor disc 24 and thru-bolt26 interfaces are visually inspected after rotor disassembly. Thethru-bolts 26 male threads that mate with the nuts 28 and the bolt outercircumference are inspected for conformity with componentspecifications. Similarly the disc 24 cavities that receive thethru-bolts 26 are visually inspected with a bore scope. During visualinspection portions of the thru-bolts 26 and disc 24 cavities may bephotographed for remote inspection by others and for archival purposes.

SUMMARY OF THE INVENTION

The inventors have recognized a need to generate images of completecircumferential surfaces of thru-bolts (including their male threads)and disc cavity recesses along their entire respective mating axiallengths for inspection evaluation and for archival purposes.

Furthermore the inventors have recognized a need to map and correlaterespective corresponding interface surfaces of the thru-bolt and of oneor more of the sequentially aligned rotor disc cavities, for bothinspection evaluation and archival purposes.

The inventors have also recognized a need and benefit of in situevaluation of thru-bolt threads, the remainder of the boltcircumferential surface and the corresponding mating rotor disc cavitycircumferential surface, without the need to disassemble the entirecorresponding rotor structure.

Accordingly, a suggested object of embodiments of the invention is tocreate apparatus and methods for inspecting and generating images ofcomplete circumferential surfaces of thru-bolts (including their malethreads) and disc cavity recesses along their entire respective matingaxial lengths.

Another object of embodiments of the invention is to create apparatusand methods for mapping and correlating respective correspondinginterface surfaces of the thio-bolt and of one or more of thesequentially aligned rotor disc cavities;

Another object of embodiments of the invention is to create apparatusand methods for in situ evaluation of thru-bolt threads, the remainderof the bolt circumferential surface and the corresponding mating rotordisc cavity circumferential surface, without the need to disassemble theentire corresponding rotor structure.

These and other objects are achieved in one or more embodiments of theinvention by a methods for inspecting turbine engine rotors with acamera inspection system that includes one or both of a thru-bolt malethreads inspection apparatus and a rotor disc cavity inspectionapparatus. The thru-bolts threads inspection apparatus engages the malethreads and advances along the bolt threads pattern, selectivelycapturing camera images at desired spatial positions along the threadspattern. The plural camera threads images are desirably combined to forma composite image of a desired portion of or the entire thru-bolt malethreads profiles, which aids their inspection evaluation and provides anarchived composite image of the profiles. The disc cavity inspectionscope apparatus is insertable in one or more of the desired rotor disccavities and orients an attached inspection camera field of viewgenerally transverse to the circumferential wall in the rotor disc thatdefines the cavity. Preferably inspection scope apparatus insertion intothe disc cavities is performed with a motion control system thatmonitors spatial position of the camera field of view relative to therecess circumferential wall. The plural camera cavity circumferentialwall images are desirably combined to form a composite image of adesired portion of or the entire disc cavity circumferential surface,which aids their inspection evaluation and provides an archivedcomposite image of the surface.

Embodiments of the invention facilitate in situ inspection of thethru-bolt and disc cavity circumferential surfaces without disassemblyof the entire rotor structure. Alternatively the inspection apparatusand methods of embodiments of the invention can be utilized ondisassembled rotor discs and thru-bolts.

Besides creating composite images of the thru-bolt male threads,embodiments of the invention capture and create composite images of theremainder of the thru-bolt circumferential surface. Desirably inembodiments of the invention, composite images of correspondingthru-bolt and cavity recess mating spatial circumferential surfaces areoriented side-by-side for inspection and component serviceabilityevaluation.

Embodiments of the invention feature a turbine engine rotor disc cavityinspection apparatus, including a scope shaft, defining a central axis,insertable in and capable of axial translation within a rotor disccavity; and a camera, coupled to the scope shaft, having a field of viewgenerally tangential to the scope shaft central axis, for capturingimages of a circumferential wall defining the rotor disc cavity.

Other embodiments of the invention feature a method for inspecting aturbine engine rotor disc cavity, by providing a rotor disc cavityinspection apparatus, including a scope shaft, defining a central axis,insertable in and capable of axial translation within a rotor disccavity; and a camera, coupled to the scope shaft, having a field of viewgenerally tangential to the scope shaft central axis. The inspectionapparatus is inserted into a rotor disc cavity and images of acircumferential wall defining the rotor disc cavity are selectivelycaptured.

Additional embodiments of the invention feature a method for inspectinga turbine engine rotor thru-bolt and rotor disc cavity componentinterconnection, generally by inspecting and imaging external malethreads of a thru-bolt and the external outer circumference of aremainder of the thru-bolt; and inspecting and imaging corresponding oneor more rotor disc cavities that circumscribe and capture the thru-bolt.Then corresponding spatially aligned portions of the bolt and disccavity images are compared in order to evaluate mating thru-bolt anddisc cavity suitability for field service. The external male threads ofa thru-bolt are inspected by providing a thru-bolt threads inspectionapparatus, including a first camera having a field of view for capturingimages of thru-bolt threads. A first data acquisition system and a firstimage processing system are coupled to the first camera. First pluralimages are captured with the first camera. The first plural capturedimages are stored in the first data acquisition system; and combinedwith the first image processing system to form a composite image of thethru-bolt threads. The external outer circumference of a remainder ofthe thru-bolt is inspected by capturing second plural images thereofwith a second camera coupled to a second data acquisition system and asecond image processing system. The second plural captured images arestored in the second data acquisition system. The second plural capturedimages are combined with the second image processing system to form acomposite image of the thru-bolt outer circumference. The rotor disccavities are inspected by providing a rotor disc cavity inspectionapparatus, including a scope shaft, defining a central axis, insertablein and capable of axial translation within a rotor disc cavity; and athird camera, coupled to the scope shaft, having a field of viewgenerally tangential to the scope shaft central axis, the third cameracoupled to a third data acquisition system and a third image processingsystem. The inspection apparatus third camera is inserted into a disccavity. Third plural images of the disc cavity circumferential wall thatdefines the rotor disc cavity are captured with the third camera. Thethird plural captured images are stored in the third data acquisitionsystem and combined with the third image processing system to form acomposite image of the disc cavity. The corresponding spatially alignedportions of the second and third composite images are combined toevaluate mating thru-bolt and disc cavity suitability for field service.Any combination of the respective first, second and third cameras, dataacquisition and/or image processing systems may be consolidated intocombined sub systems. For example a single data acquisition and/or imageprocessing system may be utilized to store and/or process first throughthird sets of images.

The respective objects and features of embodiments of the invention maybe applied jointly or severally in any combination or sub-combination.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of invention can be readily understood by considering thefollowing detailed description in conjunction with the accompanyingdrawings, in which:

FIG. 1 is a perspective view of an exemplary known combustion turbineengine, with mating thru-bolts and rotor disc cavities in the compressorand turbine sections rotors shown in partial cross section;

FIG. 2 is a schematic perspective view of an exemplary rotor disc and insitu thru-bolts, with a disc cavity inspection apparatus, in accordancewith an embodiment of the invention, inserted in a vacant disc cavityafter removal of its corresponding thru-bolt;

FIG. 3 is a perspective cross sectional view through the rotor disccavity and disc cavity inspection apparatus of FIG. 2, taken along 3-3thereof, along with a motion control system for rotating and translatingthe cavity inspection apparatus within the cavity;

FIG. 4 is a detailed view of the disc cavity inspection apparatus ofFIG. 3;

FIG. 5 is side elevational view of thru-bolts and mating nuts installedon an assembled rotor, with one in situ thru-bolt partially withdrawnfrom the rotor, its threads being inspected by a thread inspectionapparatus, in accordance with an embodiment of the invention;

FIG. 6 is a perspective view of the thru-bolt threads inspectionapparatus with a corresponding thru-bolt;

FIG. 7 is a perspective view of the thru-bolt threads inspectionapparatus of FIG. 6;

FIG. 8 is a schematic block diagram of a thru-bolt and rotor disc cavityinspection system, in accordance with an embodiment of the invention;

FIG. 9 is a schematic block diagram of a thru-bolt and rotor disc cavityinspection system, in accordance with another embodiment of theinvention; and

FIG. 10 are respective composite photographic images of portions ofspatially corresponding opposed circumferential surfaces of a thru-boltand mating rotor disc cavity, the images.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

After considering the following description, one will realize that theteachings of one or more embodiments of the invention can be readilyutilized in a camera inspection system that includes one or both of athru-bolt male threads inspection apparatus and a rotor disc cavityinspection apparatus. The thru-bolts threads inspection apparatusengages the male threads and advances along the bolt threads pattern,selectively capturing camera images at desired spatial positions alongthe threads pattern. The plural camera threads images are desirablycombined to form a composite image of a desired portion of or the entirethru-bolt male threads profiles, which aids their inspection evaluationand provides an archived composite image of the profiles. The disccavity inspection scope apparatus is insertable in one or more of thedesired rotor disc cavities and orients an attached inspection camerafield of view generally transverse to the circumferential wall in therotor disc that defines the cavity. Preferably inspection scopeapparatus insertion into the disc cavities is performed with a motioncontrol system that monitors spatial position of the camera field ofview relative to the recess circumferential wall. The plural cameracavity circumferential wall images are desirably combined to form acomposite image of a desired portion of or the entire disc cavitycircumferential surface, which aids their inspection evaluation andprovides an archived composite image of the surface.

Embodiments of the invention can be utilized to inspect steam orcombustion turbine engine rotors, the latter having both compressor andturbine section rotors. Exemplary embodiments of the invention describedin further detail herein are directed to combustion turbine compressorsection rotor inspection.

FIGS. 2-4 show an exemplary embodiment of a rotor disc cavity inspectionscope apparatus 40, which is adapted for insertion into an axiallysequentially aligned stack of rotor discs 24 through respective disccavities 30 that is defined by a respective circumferential walls. Toaid in comprehension of the operative environment of the disc cavityinspection scope 40, the rotor disc 24 is separated from it surroundingrotor discs, with all but one of the thru-bolts 26 remaining in situ.The vacant disc cavity 30 previously had its corresponding thru-boltremoved so that the cavity could be inspected, while the remainder ofthe rotor 22 remains assembled. Alternatively, the rotor 22 can bedisassembled and disc cavities 30 of one or more of the rotor discs 24can be inspected using the disc cavity inspection scope apparatus 40.

The disc cavity inspection scope 40 includes a scope shaft 42 that asshown has a generally tubular construction. Preferably the scope shaft42 is coupled to a known motion control system 43 for axiallytranslating and rotating the scope shaft, while monitoring the disccavity inspection scope 40 position relative to the disc cavity 30internal circumferences. A camera 44 is captured within a cameramounting sleeve 46 that is in turn coupled to the interior of thegenerally tubular scope shaft 42. An exemplary camera 44 is a known USBcamera with 20 to 30 power magnification and 5 megapixel or higherresolution. The scope shaft has a circumferential scope shaft window 45through with the camera lens field of view (FOV) is oriented generallytransverse to a centerline of the scope shaft 42 and the disc cavity 30,so that the camera 44 captures images of the disc cavity circumferentialsurface. An end cap 48 is secured to the distal end of the scope shaft42 with end cap screws 49.

FIGS. 5-7 show an exemplary embodiment of a thru-bolt 26 male threads 32inspection scope apparatus 50, which comprises a collar clamp formedfrom a clamp base 52 and a clamp cover 56 coupled together by clampscrews 58. The combined clamp base 52 and clamp cover 56 define a collarclamp through aperture. One or both of the clamp base 52 and clamp cover57 have respective female threads 54, 57 that are defined within itsrespected half of the clamp collar. The threads 54, 57 have threadsprofiles (e.g., threads pitch and radial projection dimensions) that arecapable of mating engagement and advancement relative to the thru-boltmale threads 32.

A camera bracket 60 is coupled to the clamp cover 56 by camera bracketscrews 62 and to camera cover 64 that in turn retains camera 66. Thecamera bracket 60 orients the camera 66 field of view on the thru-boltthreads 32, so that images of the threads can be captured by the camera.An exemplary camera 66 is a known USB camera with 20 to 30 powermagnification and 5 megapixel or higher resolution. The clamp collar56/56 is selectively positioned axially and radially relative to thethru-bolt male threads 32, so that images of any portion of the threadspattern can be captured within the camera 66 field of view. As shown inFIG. 5, the entire outer size envelope of the thru-bolt inspection scopeapparatus 50 is sufficiently small to maneuver the apparatus in spacebetween rotor discs. In this inspection method the inspected thru-bolt26 is withdrawn from its coupled axial position within the rotor discstack for sufficient inspection clearance to allow relative rotation ofthe thru-bolt and the assembled collar clamp 52/56.

Respective disc cavity inspection scope apparatus 40/camera 44 orthru-bolt threads inspection apparatus 60/camera 66 captured images areacquired and processed in the exemplary inspection system 70 that isshown in FIG. 70. Images captured in a camera field of view (FOV)transferred via USB cable 72 to data acquisition system 74, which mayinclude a known memory device. The USB cable 72 also provides power tothe camera 44/66. Alternatively, as shown in the inspection systemembodiment 70′ of FIG. 9, camera images can be transmitted by knownwireless devices and stored electrical power sources 76. The storedpower source 76 also powers the camera 44/66. In either inspectionsystem 70, 70′ embodiment the acquired plural images are processed in animage processing system 75. Separate data acquisition systems 74 andimage processing systems 75 may be utilized for each of the inspectionthio-bolt thread 40 and disc cavity scope 50 apparatuses or they can becombined in a consolidated system. The data acquisition system and imageprocessing system functions can be incorporated within a known personalcomputer or other known computational processing device, such as aclient-server data processing system.

In either inspection system 70, 70′ embodiment the acquired pluralimages are processed in an image processing system 75, which associateseach image with its relative spatial position on the respective disccavity 30 circumferential surface or thru-bolt threads 32 surface.Spatial information for each respective image is obtained from themotion control system 43 or by pre-assigned sequence of image and knowncamera position based on manual manipulation of a camera 44/66 field ofview relative to the inspected circumferential surface. In this waycomposite images of selective portions of or the entire circumferentialsurface of a disc cavity 30 circumferential surface or thru-bolt threadscan be constructed for inspection evaluation and image archiving.

Beneficially, additional images of the remainder of the thru-bolt 26outer circumferential surfaces can be acquired with a camera and thoseimages can be combined in a data acquisition system 74/image processingsystem 75 to form a composite image of selective portions of or theentire thru-bolt circumference. An exemplary rotor disc cavity/thru-boltinterface inspection method is shown in FIG. 10. A composite axial imageof a thru-bolt 26 outer circumference is axially aligned with acorresponding axial image of the mating disc cavity circumferentialsurface 30. Wear patterns on each of the respective thru-bolt 26 anddisc cavity circumferential surface 30 can be compared to evaluateserviceability of those components for future use and also to diagnosepast engine operational characteristics. While corresponding compositerelative axial images are shown in FIG. 10, other relative correspondingimage orientations can be constructed, such as 360 degreecircumferential comparison images of a zone of interest.

The rotor thru-bolt/rotor disc cavity interface inspections describedherein are performed in situ within an assembled rotor 22 bysequentially removing, capturing images of and reinstalling onethru-bolt of the array of thru-bolts. For example, a designatedthru-bolt 26 can be partially withdrawn to inspect only its male threads32 with the thread inspection scope apparatus 50. The thru-bolt 26 canbe withdrawn in its entirety or incrementally rotor disc-by-rotor discso that desired corresponding rotor disc cavities 30 can be inspectedwith the disc cavity inspection scope apparatus 40. If the thru-bolt 26is withdrawn fully from the rotor 22 its outer circumference can beimaged for beneficial inspection comparison with the corresponding discscope cavity 30 images. Alternatively the rotor 22 can be disassembledfor separate inspection of rotor discs 24 and thru-bolts 26, utilizingthe exemplary inspection apparatus 40, 50 and related inspection systems70, 70′.

Although various embodiments that incorporate the teachings of theinvention have been shown and described in detail herein, those skilledin the art can readily devise many other varied embodiments that stillincorporate these teachings. The invention is not limited in itsapplication to the exemplary embodiment details of construction and thearrangement of components set forth in the description or illustrated inthe drawings. The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that the phraseology and terminology used herein is for thepurpose of description and should not be regarded as limiting. The useof “including,” “comprising,” or “having” and variations thereof hereinis meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Unless specified or limitedotherwise, the terms “mounted,” “connected,” “supported,” and “coupled”and variations thereof are used broadly and encompass direct andindirect mountings, connections, supports, and couplings. Further,“connected” and “coupled” are not restricted to physical or mechanicalconnections or couplings.

What is claimed is:
 1. A turbine engine rotor disc cavity inspectionapparatus, comprising: a scope shaft, defining a central axis,insertable in and capable of axial translation within a rotor disccavity; and a camera, coupled to the scope shaft, having a field of viewgenerally tangential to the scope shaft central axis, for capturingimages of a circumferential wall defining the rotor disc cavity, whereinthe scope shaft includes a hollow distal end for retention of the cameratherein and a circumferential window aperture aligned with the camerafield of view, wherein a camera mounting sleeve retains the camerawithin the scope shaft hollow distal end, the camera mounting sleevebeing coupled to the interior of the scope shaft, and wherein the distalend of the scope shaft comprises an end cap coupled to the scope shafthollow distal end.
 2. The apparatus of claim 1, further comprising amotion control system, coupled to the scope shaft, for selectivelytranslating and rotating the camera field of view relative to the rotordisc cavity circumferential wall.
 3. The apparatus of claim 1, whereinthe camera comprising a USB camera having an approximately 20 to 30power magnification field of view.
 4. The apparatus of claim 1, whereinthe camera coupled to a data acquisition system for receiving imagesgenerated by the camera.